Composite material layup including trim-on-the-fly

Abstract

Disclosed is a method and apparatus for manufacturing multiple layer composite structures and structures containing components made of multiple layer composite structures, comprising dispensing layers of composite material, trimming each layer to its final shape as it is being dispensed, and positioning it properly with respect to prior layers in the part lay-up.

What is claimed is: 
     
       1. A composite lay-up system comprising:
 a trim table; 
 a feed mechanism for dispensing composite material in a first direction on the trim table; 
 a trim cutter mechanism for cutting the composite material as the material is being dispensed on the trim table, the trim mechanism including a cutter, a first actuator for moving the cutter linearly in the first direction, and a second actuator, mounted to the first actuator, for moving the cutter across the trim table in a second direction that is orthogonal to the first direction; and; 
 a lay-up table onto which the cut composite material is laid up. 
 
     
     
       2. The composite lay-up system of  claim 1  further comprising a rail and a driver for moving the lay-up table along the rail, wherein rate of table movement and dispensing rate are the same. 
     
     
       3. The composite lay-up system of  claim 1 , wherein the lay-up table is controlled to establish a start point for each layer of composite material to position it properly with respect to a previous layer of composite material. 
     
     
       4. The composite lay-up system of  claim 1 , wherein the lay-up table is shuttled to a second operating location for consolidation of multiple layers of composite material. 
     
     
       5. The composite lay-up system of  claim 1  in which the trimming system comprises at least one additional cutter mechanism for cutting in the first and second directions, the cutter mechanisms ganged together. 
     
     
       6. The composite lay-up system of  claim 1 , further comprising a third actuator, mounted to the second actuator, for moving the cutter normal to a surface of the trim table. 
     
     
       7. The composite lay-up system of  claim 6 , wherein the third actuator also rotates the cutter about the normal. 
     
     
       8. The composite lay-up system of  claim 1 , wherein the trim table is tilted with respect to the lay-up table. 
     
     
       9. The composite lay-up system of  claim 1  wherein the cutter includes an ultrasonic cutter. 
     
     
       10. The composite lay-up system of  claim 1 , wherein multi-dimensional trim cuts are made to the dispensed material within the range of motion of the first actuator without changing the speed of the material as it is being dispensed. 
     
     
       11. The composite lay-up system of  claim 1 , further comprising means for dispensing from either a first supply roll or a second supply roll, the means including a member rotatable about an axis perpendicular to the axes of rotation of the supply rolls to bring one or the other of the supply rolls into position as a feed roll. 
     
     
       12. The composite lay-up system of  claim 1 , further comprising means for removing a backing from the composite material at an interface between the trim and lay-up tables.